Crash energy absorption assembly for a motor vehicle

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/329,802, filed Oct. 16, 2001, and entitled “Modular Front End For Passenger Cars And Light Trucks, Joining An Integrated Drive Train Module, Apron-Cum Energy Module And Crash Energy Management Module To An Integrated Structural Cowl”, the full disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to motor vehicles, such as passenger cars and light trucks. More particularly, the present invention relates generally to a multi-component front end for a motor vehicle, which advances the methods by which motor vehicles are assembled.

2. Description of Related Art

Currently, the front ends of most motor vehicles are built into the vehicle body one piece or component at a time. The installation of literally hundreds of different components in the motor vehicle front end requires the manufacturer to maintain lengthy, complex, and costly assembly lines as well as extensive tooling and fixtures. This complexity is due not only to the high number of parts involved, but also the assembly methods currently used in the automotive industry and the amount of on-line adjusting and repair that is often needed to correct assembly defects. Additionally, the well-known assembly line process is highly labor intensive, again due mainly to the high number of parts and assembly methods currently used in the automotive industry.

Typically, once a painted vehicle body comes to the finish assembly line, hundreds of individual components are assembled to the vehicle body. The numerous individual components are used to complete the suspension system, steering and braking system, power train, cooling system, electrical system, etc. As stated, the individual components comprising these systems are typically added to the vehicle body one-by-one or in small subgroups to finish the assembly of the motor vehicle.

The large number of components required to assemble a motor vehicle requires the assembly line to be extremely long and requires many people to accomplish numerous discreet tasks along the assembly line. This makes the process of motor vehicle assembly unnecessarily slow and complicated and adversely affects the quality and reliability of the motor vehicle when it is completed. Additionally, the confined space within which the workers operate makes on-line service and repair tasks difficult and even dangerous. The overall complexity of the current system for assembling motor vehicles is unnecessarily slow and expensive and there is considerable room for improvement.

SUMMARY OF THE INVENTION

The present invention applies the general concept of using modules or assemblies in the manufacturing of motor vehicles. The concepts and embodiments disclosed hereinafter may be applied to other industries that utilize the long-standing assembly line technique for producing finished products, such as the aircraft, agricultural machinery, truck manufacturing, and mining vehicle industries. Generally, the present invention is a motor vehicle comprising a vehicle body having a pre-assembled, modular front end. The modular front end is comprised of several sub-modules or sub-assemblies, as discussed hereinafter.

The modular front end is based on the concept of “functionally decoupling” the several sub-modules or sub-assemblies from each other. In front end assembly techniques currently practiced in the art, the various elements or components of the front end are substantially interconnected or related. In contrast, the modular front end of the present invention has the various sub-assemblies comprising the front end substantially functionally isolated from one another. The separate functions of the sub-assemblies, which will be discussed hereinafter, are substantially independent from one another allowing any one sub-module or sub-assembly to be individually replaced without affecting the other sub-modules or sub-assemblies. This allows the sub-modules or sub-assemblies to be comprised of smaller and lighter individual components or parts, which is not easily possible in the “interrelated” front end structures generally found in the prior art. The use of separate and distinct sub-modules or sub-assemblies in the modular front end allows the overall size of the modular front end to be reduced because the sub-assemblies may be compact tightly within the modular front end. The smaller front end made possible by the modular front end of the present invention improves the overall driving and handling characteristics of the motor vehicle. For example, the smaller front end is lower in profile than those currently known in the art, which improves the driver's view of the road and aids the driver in performing routine vehicle operations such as parking, turning, etc.

Generally, the modular front end comprises a bulkhead having a plurality of preferably integrally formed attachment mounts, a drive train assembly attached to the bulkhead at the attachment mounts, a crash energy absorption assembly attached to the bulkhead at the attachment mounts and, further, an apron assembly attached to the bulkhead assembly at the attachment mounts. The apron assembly may be at least partially supported in the vertical direction by the crash energy absorption assembly. The drive train assembly, crash energy absorption assembly, and apron assembly are each preferably attached mechanically to the bulkhead.

The bulkhead is preferably a cast bulkhead comprising a plurality of integrally formed attachment mounts. The bulkhead may be cast from aluminum alloy as a unitary body. The bulkhead may also be comprised of a plurality of individually cast components. The bulkhead may be provided as part of a bulkhead assembly. The bulkhead assembly may comprise a cast bulkhead defining a plurality of integrally formed attachment mounts and at least one structural member of the motor vehicle attached to the bulkhead. The bulkhead assembly may further include one or more electrical components attached to the bulkhead.

The bulkhead may define at least one hollow cavity formed therein for increasing strength and rigidity of the bulkhead. The at least one hollow cavity may be filled with a cast-in-place core, preferably an aluminum foam core. The hollow cavity may also be filled with polymeric foam. The at least one structural member may comprise a pair of door hinge pillars attached to attachment mounts located at opposite ends of the bulkhead. The at least one structural member may also comprise a pair of rocker panels attached to a bottom end of the bulkhead opposite the door hinge pillars. Additionally, the at least one structural member may comprise a pair of windshield support pillars attached to a top end of the bulkhead. The at least one structural member may further comprise a windshield cross member attached to the top end of the bulkhead between the windshield support pillars.

The bulkhead may comprise a first side for facing an engine compartment of the motor vehicle and a second side for facing a passenger compartment of the motor vehicle. A pair of hood hinges, which may each include a hood lift assist mechanism, may be attached to attachment mounts located on the first side of the bulkhead for supporting a hood of the motor vehicle. The electrical component(s) is preferably attached to the first side of the bulkhead, but may be attached to the second side facing the passenger compartment. The electrical component(s) may include, for example, a windshield wiper motor and/or an electrical junction box.

The drive train assembly generally comprises a drive train support and a power train assembly attached to the drive train support. The drive train support comprises a pair of elongated support members that are configured for attachment, preferably by mechanical means, to a bulkhead of the motor vehicle. By mechanical attachment or means, it is meant that mechanical fasteners, such as nuts and bolts, rivets, and the like are preferably used to attach the various elements described in this disclosure, and may include rubber isolation mounts (i.e., bushings), where necessary, to minimize vibration between elements. The drive train support further comprises a cross member interconnecting the support members. The support members are further configured to support the power train assembly such that the power train assembly is cantilevered from the support members and bulkhead forward of the cross member.

The support members and cross member may be made of aluminum alloy. The support members may be cast aluminum alloy support members. The cross member may be an extruded aluminum alloy cross member. The support members each comprise a top end and a bottom end. The cross member preferably connects the top ends of the support members. The cross member may be connected mechanically to the support members.

In the modular front end, the power train assembly is attached to the support members such that the power train assembly is cantilevered from the support members and bulkhead forward of the cross member. The support members may be attached mechanically to the bulkhead. The mechanical attachment may comprise at least one isolation mount for dampening vibration of the power train assembly. The power train assembly may comprise an engine and transmission of the motor vehicle. The engine may be mechanically attached to the drive train support and comprise at least one isolation mount for dampening vibration of the engine. The transmission may be mechanically attached to the drive train support and comprise at least one isolation mount for dampening vibration of the transmission. The drive train assembly may further comprise a steering gear of the motor vehicle attached to the bottom ends of the support members and interconnecting the bottom ends of the support members. Further, the drive train assembly may comprise a brake and suspension assembly for each front wheel of the motor vehicle. The brake and suspension assemblies are attached to the support members, respectively, and preferably the lower ends of the support members. The brake and suspension assemblies may each comprise a control arm connected to the respective support members, preferably mechanically.

The crash energy absorption assembly generally comprises an elongated bumper beam, a pair brackets attached to the bumper beam, and a pair of tubes supported by the brackets. The tubes each have a first end and a second end. The first ends of the tubes are supported by the brackets. The second ends of the tubes may be attached to the bulkhead at the attachment mounts. A crosstie may interconnect the brackets. The bumper beam, brackets, and tubes may be made of aluminum alloy.

The bumper beam may define a substantially open cross section, which may be at least partially, but preferably completely, filled with polymeric foam. The bumper beam may define a substantially Σ-shaped cross section. The substantially Σ-shaped cross section may comprise a rear wall connected to substantially parallel top and bottom walls. The brackets may be attached to the bumper beam opposite the rear wall.

The tubes may be at least partially filled with polymeric foam. The tubes may comprise a tube with a cross-sectional profile selected from the group consisting of a circle, a square, an oval, a rectangle, a hexagon, and a combination thereof The tubes may have different cross-sectional profiles. The brackets are preferably attached mechanically to the bumper beam. The brackets may define sockets configured to receive the first ends of the tubes. The tubes may be secured mechanically in the sockets. The bumper beam may define an overall curved shape. In the modular front end, the second ends of the tubes are attached to the bulkhead at the attachment mounts. The brackets may be taper and flare brackets, which absorb impact energy using the taper and flare principle known in the art. Alternatively, the brackets may be conventional brackets and the tubes may be crush tubes for absorbing crash energy during a collision.

The apron assembly generally comprises an apron and, preferably, at least one engine accessory of the motor vehicle attached to the apron. The apron generally comprises a substantially C-shaped, unitary apron member having a depending front portion and a substantially C-shaped apron rail attached to a top end of the apron member. The apron member defines at least one integrally formed accessory attachment mount for mounting the at least one engine accessory of the motor vehicle. The apron rail is attached to the top end of the apron member and is configured for attachment to the bulkhead. Preferably, the ends of the apron rail are attached to the bulkhead. The apron rail may be configured for mechanical attachment to the bulkhead The apron rail is preferably attached mechanically to the apron member. The apron member is preferably formed of molded plastic material and the apron rail is preferably made of aluminum alloy. The apron rail may be a hydro-formed tube defining differing cross-sectional areas along its length, which provide mounting locations for various front end components of the motor vehicle such as the vehicle fenders. The at least one accessory attachment mount may comprise a plurality of openings defined in the front portion of the apron member.

The at least one engine accessory may be a radiator and cooling fan assembly and the accessory attachment mount may be an opening defined in the front portion of the apron member. The radiator and cooling fan is supported in the opening. The at least one engine accessory may be an air conditioning condenser and the attachment mount may be a second opening defined in the front portion of the apron member. The air conditioning condenser is supported in the second opening. Additionally, the at least one engine accessory may be a transmission oil cooler and the accessory attachment mount may be a third opening defined in the front portion of the apron member. The transmission oil cooler is supported in the third opening. Further, the at least one engine accessory may be a battery and the accessory attachment mount may be an integrally formed battery hold-down. The battery is supported in the battery hold down. The apron assembly may further comprise fenders attached to the apron rail and/or headlights attached to the front portion of the apron member. Other possible engine accessories include fluid reservoirs for the radiator and cooling assembly, windshield wiper fluid etc.

The present invention is also a method of assembling a modular front end for a motor vehicle. The method comprises the steps of providing a bulkhead having a plurality of attachment mounts; attaching a drive train assembly to the bulkhead at the attachment mounts; attaching a crash energy absorption assembly to the bulkhead at the attachment mounts; and attaching an apron assembly to the bulkhead at the attachment mounts. The bulkhead may be pre-attached to the vehicle body and the various assemblies identified hereinabove assembled to the pre-attached bulkhead. Thus, the step of providing the bulkhead includes both a separate, stand alone bulkhead that is to be attached to a vehicle body, and a bulkhead that is pre-attached to a vehicle body.

The method may further comprise the step of casting the bulkhead as a unitary bulkhead. The attachment mounts are preferably formed integrally with the unitary bulkhead. The bulkhead may be cast from aluminum alloy. The method may further comprise the step of attaching at least one structural member of the motor vehicle to the bulkhead.

The bulkhead may comprise a first side for facing an engine compartment of the motor vehicle and a second side for facing a passenger compartment of the motor vehicle. The method may comprise the step of attaching at least one electrical component of the motor vehicle to the first side of the bulkhead. The drive train assembly, crash energy absorption assembly, and apron assembly may be attached mechanically to the attachment mounts located on the first side of the bulkhead.

The drive train assembly may comprise a drive train support and a power train assembly. The power train assembly may comprise an engine and a transmission of the motor vehicle attached to the drive train support. The step of attaching the drive train assembly to the bulkhead may comprise attaching the drive train support to the bulkhead at the attachment mounts such that the power train assembly is cantilevered from the drive train support and bulkhead. The power train support may comprise a pair of support members each having a top end and a bottom end and a cross member connecting the top ends of the support members. The method may further comprise the step of attaching a steering gear of the motor vehicle to the bottom ends of the support members to interconnect the support members. The drive train assembly may further comprise a brake and suspension assembly for each front wheel of the motor vehicle. Further, the method may comprise the step of attaching the brake and suspension assemblies to the support members, respectively.

The crash energy absorption assembly may comprise an elongated bumper beam, a pair of brackets attached to the bumper beam, and a pair of tubes each having a first end and a second end. The first ends of the tubes may be supported by the brackets. The step of attaching the crash energy absorption assembly to the bulkhead may comprise attaching the second ends of the tubes to attachment mounts preferably located on the first side of the bulkhead.

The apron assembly may be partially supported in the vertical direction by the crash energy absorption module. The apron assembly may comprise an apron member and at least one engine accessory of the motor vehicle attached to the apron member. The method may further comprise the step of attaching the at least one engine accessory of the motor vehicle to the apron member. The at least one engine accessory may be a radiator and cooling fan assembly, an air conditioning condenser, a transmission oil cooler, and/or a battery. Other possible engine accessories include fluid reservoirs for the radiator and cooling assembly, windshield wiper fluid etc. The apron member may be substantially C-shaped and have a depending front portion. The apron assembly may further comprise a substantially C-shaped apron rail. The method may comprise the step of attaching the apron rail to a top end of the apron member. The ends of the apron rail may be configured for connection to the bulkhead at the attachment mounts. The step of attaching the apron assembly to the bulkhead may comprise attaching the ends of the apron rail to the bulkhead at the attachment mounts. Furthermore, the method may comprise the steps of attaching one or more fenders of the motor vehicle to the apron rail, and attaching headlights of the motor vehicle to the front portion of the apron member.

Further details and advantages of the present invention will become apparent from the following detailed description when read in conjunction with the drawings, wherein like parts are designated with like reference numerals throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

<figref idref="DRAWINGS">FIG. 1</figref> is a perspective view of a motor vehicle having a modular front end in accordance with the present invention;

<figref idref="DRAWINGS">FIG. 2</figref> is a perspective view of the modular front end shown in <figref idref="DRAWINGS">FIG. 1</figref>;

<figref idref="DRAWINGS">FIG. 3</figref> is a perspective view of a bulkhead assembly used in the modular front end of <figref idref="DRAWINGS">FIGS. 1 and 2</figref>;

<figref idref="DRAWINGS">FIG. 4</figref> is a perspective view of a bulkhead used in the bulkhead assembly of <figref idref="DRAWINGS">FIG. 3</figref> showing the passenger compartment facing side of the bulkhead;

<figref idref="DRAWINGS">FIG. 5</figref> is a perspective view of the bulkhead used in the bulkhead assembly of <figref idref="DRAWINGS">FIG. 3</figref> showing the engine compartment facing side of the bulkhead;

<figref idref="DRAWINGS">FIG. 6</figref> is a perspective view of the bulkhead assembly generally showing the engine compartment facing side of the bulkhead;

<figref idref="DRAWINGS">FIG. 7</figref> is a perspective view of the bulkhead assembly generally showing the passenger compartment facing side of the bulkhead;

<figref idref="DRAWINGS">FIG. 8</figref> is a perspective view of a drive train assembly used in the in the modular front end of <figref idref="DRAWINGS">FIGS. 1 and 2</figref>;

<figref idref="DRAWINGS">FIG. 9</figref> is a side view of the drive train assembly of <figref idref="DRAWINGS">FIG. 8</figref>;

<figref idref="DRAWINGS">FIG. 10</figref> is a perspective view of a drive train support used in the drive train assembly of <figref idref="DRAWINGS">FIG. 8</figref>;

<figref idref="DRAWINGS">FIG. 11</figref> is a perspective view of the drive train support of <figref idref="DRAWINGS">FIG. 10</figref> generally viewed from the opposite or reverse side;

<figref idref="DRAWINGS">FIG. 12</figref> is a perspective view of the drive train assembly of <figref idref="DRAWINGS">FIG. 8</figref> with the bulkhead removed and showing the various components of the drive train assembly;

<figref idref="DRAWINGS">FIG. 13</figref> is a bottom view of the drive train assembly of <figref idref="DRAWINGS">FIG. 8</figref>;

<figref idref="DRAWINGS">FIG. 14</figref> is a perspective view of a crash energy absorption assembly used in the modular front end of <figref idref="DRAWINGS">FIGS. 1 and 2</figref>;

<figref idref="DRAWINGS">FIG. 15</figref> is a second perspective view of the crash energy absorption assembly used in the in the modular front end of <figref idref="DRAWINGS">FIGS. 1 and 2</figref>;

<figref idref="DRAWINGS">FIG. 16</figref> is a perspective view of an apron assembly used in the in the modular front end of <figref idref="DRAWINGS">FIGS. 1 and 2</figref>;

<figref idref="DRAWINGS">FIG. 17</figref> is a perspective view showing an apron of the apron assembly of <figref idref="DRAWINGS">FIG. 16</figref>;

<figref idref="DRAWINGS">FIG. 18</figref> is a perspective view of the apron assembly of <figref idref="DRAWINGS">FIG. 16</figref> generally viewed from the opposite or reverse side;

<figref idref="DRAWINGS">FIG. 19</figref> is a perspective view of the apron assembly of <figref idref="DRAWINGS">FIG. 16</figref> further showing a fender and headlights of the motor vehicle attached to the apron assembly;

<figref idref="DRAWINGS">FIG. 20</figref> is a perspective view of the modular front end of <figref idref="DRAWINGS">FIGS. 1 and 2</figref> showing only the structural components of the various assemblies; and

<figref idref="DRAWINGS">FIG. 21</figref> is a second perspective view of the modular front end shown in FIG. <b>20</b>.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, and derivatives thereof shall relate to the invention, as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternatives and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific elements and processes illustrated in the drawings, and described in the following specification, are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered alimiting.

Referring to <figref idref="DRAWINGS">FIGS. 1 and 2</figref>, a motor vehicle <b>1</b> comprising a modular front end <b>10</b> in accordance with the present invention is shown. Only the front portion of the motor vehicle <b>1</b> is shown, but the remainder of the motor vehicle <b>1</b> is conventional. The modular front end <b>10</b> forms the complete front portion of the motor vehicle <b>1</b>. Once assembled, the modular front end <b>10</b> may be attached to the body of the motor vehicle <b>1</b> substantially in one step, significantly increasing the efficiency of assembling the motor vehicle <b>1</b>. The modular front end <b>10</b> preferably arrives pre-assembled to the assembly line where it is joined to the body of the motor vehicle <b>1</b>. The modular front end <b>10</b> allows the length of the assembly line to be reduced because the large number of parts typically found in the front end of the motor vehicle <b>1</b> is now consolidated into several sub-modules or sub-assemblies, each of which is described in detail hereinafter. The modular front end <b>10</b> also reduces the assembly equipment and the number of workers required to manufacture the motor vehicle <b>1</b>. Further, the individual assemblies comprising the modular front end <b>10</b> may be tested for performance prior to their installation in the modular front end <b>10</b>, which improves the overall quality of the motor vehicle <b>1</b>.

The modular front end <b>10</b> is generally comprised of four (4) separate sub-modules or assemblies. The four distinct modules include a bulkhead assembly <b>100</b>, a drive train assembly <b>200</b>, a crash energy absorption assembly <b>300</b>, and an apron assembly <b>400</b>. The bulkhead assembly <b>100</b> generally provides the structural support for mounting and supporting the other assemblies <b>200</b>, <b>300</b>, <b>400</b>. The drive train assembly <b>200</b> is directly attached to the bulkhead assembly <b>100</b> The crash energy absorption assembly <b>300</b> is positioned generally around the lower portion of the drive train assembly <b>200</b> and is also directly attached to the bulkhead assembly <b>100</b>. The apron assembly <b>400</b> is generally positioned on top of the drive train assembly <b>200</b> and the crash energy absorption assembly <b>300</b>, and generally surrounds the drive train assembly <b>200</b>. Each of the assemblies <b>100</b>-<b>400</b> will be discussed in detail hereinafter, as well as a preferred method of assembling the modular front end <b>10</b> of the motor vehicle <b>1</b>.

The various assemblies <b>100</b>-<b>400</b> are independent of one another or “functionally decoupled” from one another and are generally interrelated by their connection to the bulkhead assembly <b>100</b>, which provides the structural support for the other assemblies <b>200</b>-<b>400</b>. The bulkhead assembly <b>100</b> may be provided separately from or pre-attached to the body of the motor vehicle <b>1</b>. Thus, the modular front end <b>10</b> may be pre-assembled and attached to the body of the motor vehicle <b>1</b>, or the bulkhead assembly <b>100</b> may be pre-attached to the body of the motor vehicle <b>1</b> and the other assemblies <b>200</b>-<b>400</b> then attached to the bulkhead assembly <b>100</b>.

Referring to <figref idref="DRAWINGS">FIGS. 1-7</figref>, the bulkhead assembly <b>100</b> is generally comprised of a cast, preferably unitary, bulkhead <b>102</b> and a plurality of components or parts, such as structural members of the motor vehicle, attached to the bulkhead <b>102</b>. The bulkhead <b>102</b> serves as the base structural component that the supports the drive train assembly <b>200</b>, the crash energy absorption assembly <b>300</b>, and the apron assembly <b>400</b>.

The unitary bulkhead <b>102</b> is preferably an ultra-large casting of aluminum or aluminum alloy or a similar material such as magnesium alloy, or formed of fiber reinforced polymer composite materials. The bulkhead <b>102</b> is a unitary bulkhead that replaces the typical 10 to 15 stamped steel parts typically used in existing bulkhead designs. The use of aluminum and aluminum alloys reduces the weight of bulkhead <b>102</b> in comparison to traditional bulkhead designs. The bulkhead <b>102</b> may also be formed of multiple cast components, each preferably cast from aluminum alloy, and joined together by means customary in the art.

The bulkhead <b>102</b> is preferably cast with one or more hollow cavities <b>104</b> formed therein for increasing the strength and rigidity of the bulkhead <b>102</b>. The hollow cavity <b>104</b> may be filled with a cast-in-place core or polymeric foam <b>106</b>. The cast-in-place core <b>106</b> is preferably aluminum foam. When polymeric foam is used, the polymeric foam <b>106</b> is filled into the hollow cavity <b>104</b> after casting. The cast-in-place aluminum foam core or polymeric foam <b>106</b> increases the strength and stiffness of the system but also reduces the chance of internal corrosion in the bulkhead <b>102</b>. The bulkhead <b>102</b> is generally rectangular shaped and has opposite lateral ends <b>108</b>, <b>110</b>, and top and bottom ends <b>112</b>, <b>114</b>. The top end <b>112</b> of the bulkhead <b>102</b> may define a longitudinally extending opening <b>116</b>, which may be used to route heating and ventilating ducting as well as providing a drainage conduit for water flowing off the windshield of the motor vehicle <b>1</b>. The rectangular shaped bulkhead <b>102</b> has a first side <b>118</b> and a second side <b>120</b>. The first side <b>118</b> faces an engine compartment <b>122</b> defined by the modular front end <b>10</b>, and the second side <b>120</b> faces a passenger compartment <b>124</b> of the motor vehicle <b>1</b>.

The bulkhead <b>102</b> is preferably cast to have a plurality of integrally formed attachment mounts <b>126</b>. The attachment mounts <b>126</b> provide locations for attaching the drive train assembly <b>200</b>, the crash energy absorption assembly <b>300</b>, and the apron assembly <b>400</b> to the bulkhead <b>102</b>. Additionally, the attachment mounts <b>126</b> provide locations for attaching additional components of the bulkhead assembly <b>100</b> to the bulkhead <b>102</b>. These additional components, discussed hereinafter, may also be attached directly to the top and bottom ends <b>112</b>, <b>114</b> and first and/or second sides <b>118</b>, <b>120</b> of the bulkhead <b>102</b>. The integral attachment mounts <b>126</b> generally provide specific locations for mounting the various assemblies <b>200</b>, <b>300</b>, <b>400</b>.

The bulkhead assembly <b>100</b> further includes additional parts or components, such as structural members <b>128</b> or electrical components <b>130</b>, of the motor vehicle <b>1</b>. The structural members <b>128</b> may include, but are not limited to, a pair of door hinge pillars <b>132</b>, <b>134</b>, a pair of rocker panels <b>136</b>, <b>138</b>, a pair of windshield support pillars <b>140</b>, <b>142</b>, and a windshield cross member <b>144</b>, each mounted to the bulkhead <b>102</b>. The electrical components <b>130</b> may include, but are not limited to, an electrical junction box <b>146</b> and a windshield wiper motor <b>148</b>.

The pair of door hinge pillars <b>132</b>, <b>134</b> is mounted to the opposite ends <b>108</b>, <b>110</b> of the bulkhead <b>102</b>. The door hinge pillars <b>132</b>, <b>134</b> are mounted to four (4) attachment mounts <b>126</b><i>dp </i>located on each of the opposite ends <b>108</b>, <b>110</b> of the bulkhead <b>110</b>. The door hinge pillars <b>132</b>, <b>134</b> provide mounting locations for mounting the doors of the motor vehicle <b>1</b>.

The pair of rocker panels <b>136</b>, <b>138</b> is mounted the bulkhead <b>102</b> generally opposite from the door hinge pillars <b>132</b>, <b>134</b>. The rocker panels <b>136</b>, <b>138</b> are located and attached to the bottom end <b>114</b> of the bulkhead <b>102</b>. The rocker panels <b>102</b> are, in turn, connected to the body of the motor vehicle <b>1</b> in a conventional manner.

The pair of windshield support pillars <b>140</b>, <b>142</b> is mounted at the top end <b>112</b> of the bulkhead <b>102</b>. Preferably, the windshield support pillars <b>140</b>, <b>142</b> are mounted to two integral attachment mounts <b>126</b><i>wp </i>located at the top end <b>112</b> of the bulkhead <b>102</b>. The windshield support pillars <b>140</b>, <b>142</b> are used to support a windshield <b>150</b> of the motor vehicle <b>1</b>, as shown in FIG. <b>3</b>. The windshield cross member <b>144</b> is also mounted at the top end <b>112</b> of the bulkhead <b>102</b> between the windshield support pillars <b>140</b>, <b>142</b> to further support the windshield <b>150</b>.

A pair of hood hinges <b>152</b> may be mounted to two (2) attachment mounts <b>126</b><i>hh </i>located on the first side <b>118</b> of the bulkhead <b>102</b>. The hood hinges <b>152</b> support a hood (not shown) of the motor vehicle <b>1</b> in a conventional manner, and may each include hood-lift assist mechanisms (i e., air cylinders or springs), which are conventional in the art.

As stated previously, various electrical components <b>130</b> of the motor vehicle <b>1</b> may be attached to the bulkhead <b>102</b>. In <figref idref="DRAWINGS">FIG. 3</figref>, two exemplary electrical components <b>130</b> of the motor vehicle <b>1</b> are shown attached to the first side <b>118</b> of the bulkhead <b>102</b>. The electrical components <b>130</b> shown include the electrical junction box <b>146</b> and the windshield wiper motor <b>148</b> of the motor vehicle <b>1</b>. Additional attachment mounts <b>126</b> formed on the first side <b>118</b> of the bulkhead <b>126</b> are used as attachment points for the drive train assembly <b>200</b>, crash energy absorption assembly <b>300</b>, and apron assembly <b>400</b>, as discussed hereinafter.

Referring to <figref idref="DRAWINGS">FIGS. 1-3</figref> and <b>8</b>-<b>13</b>, the drive train assembly <b>200</b> is attached to the first side <b>118</b> of the bulkhead <b>102</b> at four (4) specific attachment mounts <b>126</b><i>a</i>, <b>126</b><i>b</i>, <b>126</b><i>c</i>, <b>126</b><i>d </i>formed on the first side <b>118</b>, which are adapted to support the weight of the drive train assembly <b>200</b>. The drive train assembly <b>200</b> is generally comprised of a drive train support <b>202</b> and a power train assembly <b>204</b> attached to the drive train support <b>202</b>. The drive train support <b>202</b> is comprised of a pair of elongated support members <b>206</b>, <b>208</b>, which are preferably mechanically attached to the bulkhead <b>102</b> at the four (4) specific attachment mounts <b>126</b><i>a-d </i>on the first side <b>118</b> of the bulkhead <b>102</b>. Each of the support members <b>206</b>, <b>208</b> has two (2) points of connection <b>209</b> to the bulkhead <b>102</b>. Preferably, the points of connection <b>209</b> between the support members <b>206</b>, <b>208</b> and the attachment mounts <b>126</b><i>a-d </i>on the bulkhead <b>102</b> each include a rubber isolation bushing or mount <b>211</b> for reducing vibration between the bulkhead <b>102</b> and the drive train assembly <b>200</b>. These attachments are designed to be in orthogonal directions. The support members <b>206</b>, <b>208</b> are preferably cast aluminum or aluminum alloy support members. However, the support members <b>206</b>, <b>208</b> may be cast from other similar metals such as magnesium and alloys thereof or ferrous containing metals and even non-metallic materials such as fiber reinforced polymer composite materials.

A cross member <b>210</b> interconnects the support members <b>206</b>, <b>208</b>. The cross member <b>210</b> is preferably mechanically connected to the support members <b>206</b>, <b>208</b>. As used in this disclosure, the terms “mechanically”, “mechanically connected”, or “mechanical means” and similar phrases are intended to mean the use of mechanical fasteners such as nuts, bolts, rivets, and the like, and their substantial equivalents, and may include the use of vibration isolation joints such as rubber bushings or similar resilient structures as necessary to reduce vibration and noise. The cross member <b>210</b> is preferably an extruded aluminum alloy cross member, but may be a cast article and may be made of any of the materials listed previously in connection with the support members <b>206</b>, <b>208</b>. The support members each have a top or upper end <b>212</b> and a bottom or lower end <b>214</b>. The cross member <b>210</b> preferably connects the top or upper ends <b>212</b> of the support members <b>206</b>, <b>208</b>.

The power train assembly <b>204</b> is supported entirely by the support members <b>206</b>, <b>208</b> and bulkhead <b>102</b> in the modular front end <b>10</b>. There is at least one and, preferably, multiple points of connection between the power train assembly <b>204</b> and drive train support <b>202</b>, as discussed hereinafter. As indicated previously, there are preferably four (4) points of connection between the drive train support <b>202</b> and the bulkhead <b>102</b> at attachment mounts <b>126</b><i>a-d</i>. The support members <b>206</b>, <b>208</b> are attached to the bulkhead <b>102</b> and generally extend vertically along the bulkhead <b>102</b>. Thus, the power train assembly <b>204</b> is cantilevered from the support members <b>206</b>, <b>208</b> and the bulkhead <b>102</b> in the modular front end <b>10</b>. By “cantilevered” it is meant that the center of gravity of the power train assembly <b>204</b> is positioned outward from the bulkhead <b>102</b> and drive train support <b>202</b>. The attachment mounts <b>126</b><i>a-d </i>at the top and bottom ends <b>112</b>, <b>114</b> of the bulkhead <b>102</b> provide the vertical support for the power train assembly <b>204</b>. The attachment mounts <b>126</b><i>a</i>, <b>126</b><i>b </i>located at the bottom end <b>114</b> of the bulkhead <b>102</b> are horizontally oriented so that the power train assembly <b>204</b> is supported in two planes, horizontal and vertical.

In summary, the power train assembly <b>204</b> is substantially supported in a “cantilevered” fashion by a substantially vertically oriented power train support <b>202</b>, which is connected to the bulkhead <b>102</b> mechanically. This is in contrast to typical engine support arrangements currently used in the automotive industry in which a horizontally extending engine cradle supports the engine of the motor vehicle. The engine cradle in known engine support arrangements is rigidly connected to the frame of the motor vehicle and supports the engine from underneath.

The power train assembly <b>204</b> generally includes an engine <b>216</b> and a transmission <b>218</b> of the motor vehicle <b>1</b>. The engine <b>216</b> has numerous components associated therewith, such as an engine manifold <b>220</b> and an engine exhaust <b>222</b>. In this disclosure, the term “engine” <b>204</b> is meant to include the power generating unit of the motor vehicle <b>1</b> as well as any accessories directly connected thereto necessary for generating power for the motor vehicle <b>1</b>. The engine <b>216</b> and transmission <b>218</b> are mechanically attached to the support members <b>206</b>, <b>208</b> at multiple connection or mounting points <b>219</b> as best shown <figref idref="DRAWINGS">FIGS. 11 and 12</figref>. The mounting points <b>219</b> may be vibration-isolated through the use of a plurality of rubber isolation bushings or mounts <b>221</b>, again as best shown in <figref idref="DRAWINGS">FIGS. 11 and 12</figref>.

Additional components of the modular front end <b>10</b> may be supported on the drive train support <b>202</b>, either directly or indirectly. For example, the drive train assembly <b>200</b> may further comprise a steering gear <b>224</b> of the motor vehicle <b>1</b>. The steering gear <b>224</b> of the motor vehicle <b>1</b> is housed within a housing <b>225</b>. The steering gear <b>224</b> is attached to the bottom ends <b>214</b> of the support members <b>206</b>, <b>208</b>, with the housing <b>225</b> interconnecting the support members <b>206</b>, <b>208</b> at the lower end <b>214</b> of each of the support members <b>206</b>, <b>208</b>. The support members <b>206</b>, <b>208</b>, cross member <b>210</b>, and steering gear <b>224</b> and housing <b>225</b> form a solid four (4) sided frame for supporting the power train assembly <b>204</b>. The steering gear <b>224</b> is conventional in the art and is configured to be connected to the steering column (not shown) of the motor vehicle <b>1</b>

The motor vehicle <b>1</b> comprises two front wheels <b>226</b>, <b>228</b>. A brake and suspension assembly <b>230</b> is associated with each of the front wheels <b>226</b>, <b>228</b> to interconnect the front wheels <b>226</b>, <b>228</b> to the drive train assembly <b>200</b> and, more particularly, the drive train support <b>202</b>. The brake and suspension assembly <b>230</b> generally includes the components necessary to apply braking to the front wheels <b>226</b>, <b>228</b>, and interconnect the front wheels <b>226</b>, <b>228</b> to the drive train assembly <b>200</b>. The front wheels <b>226</b>, <b>228</b> are respectively connected to two power train shafts <b>232</b>, <b>234</b>, which extend outward from the transmission <b>218</b> and provide power to the front wheels <b>226</b>, <b>228</b>.

The brake and suspension assemblies <b>230</b> each include a knuckle <b>236</b>, a braking assembly <b>238</b> connected to the knuckle <b>236</b>, and a lower control arm <b>240</b> connected to the knuckle <b>236</b>. A sway bar <b>242</b> may interconnect the two (2) brake and suspension assemblies <b>230</b>. The knuckle <b>236</b> for each of the assemblies <b>230</b> is conventional and may be connected by a shock absorber and spring assembly <b>244</b> to the top end <b>212</b> of the support members <b>206</b>, <b>208</b> in each assembly <b>230</b>. The braking assembly <b>238</b> (i.e., rotor, caliper etc.) is also conventional and is supported by the knuckle <b>236</b> in each of the assemblies <b>230</b>. The knuckle <b>236</b> in each assembly <b>230</b> is connected to the lower end <b>214</b> of the respective support members <b>206</b>, <b>208</b> by the respective lower control arms <b>240</b>. The lower control arms <b>240</b> are connected to the respective support members <b>206</b>, <b>208</b> mechanically, such as with bushings <b>246</b>. The bushings <b>246</b> may be rubber isolation bushings or mounts as are known in the art. The lower control arm <b>240</b> shown on the passenger's or left side of the drive train assembly <b>200</b> (top portion of <figref idref="DRAWINGS">FIG. 13</figref>) is the subject matter of U.S. patent application Ser. No. 10/271,449 filed the same day as this application, Oct. 16, 2002, and entitled “Control Arm For Motor Vehicle Suspension System”, and naming Dinesh C. Seksaria and John W. Cobes as inventors. The disclosure of the foregoing United States Patent Application is incorporated fully herein by reference.

The drive train assembly <b>200</b> contains each of the components required to make the motor vehicle <b>1</b> move, stop, and steer. The drive train support <b>202</b> is specifically adapted to support the engine <b>216</b> and transmission <b>218</b> in the vertical direction, such that the engine <b>216</b> and transmission <b>218</b> are cantilevered from the bulkhead <b>102</b>, as defined previously. The bulkhead <b>102</b> generally separates the engine compartment <b>122</b> from the passenger compartment <b>124</b> in the motor vehicle <b>1</b>. The engine <b>216</b> and transmission <b>218</b> are now located directly in front of the bulkhead <b>102</b> providing an extra layer of protection for occupants of the passenger compartment <b>124</b> in the event of a front end collision. Additionally, the engine <b>216</b>, transmission <b>218</b>, steering gear <b>224</b>, and brake and suspension assemblies <b>230</b> for the two front wheels <b>226</b>, <b>228</b> are all now compacted tightly within a single sub-assembly, which may be pre-tested as a unit before assembly to the motor vehicle <b>1</b> The compact nature of the drive train assembly <b>200</b> also provides a more direct and shorter path for exhaust gases from the engine <b>216</b>, which improves performance and fuel efficiency of the engine <b>216</b> while reducing emissions. The compact form of the drive train assembly <b>200</b> frees up additional space for expanding the passenger compartment <b>124</b> of the motor vehicle <b>1</b>. Furthermore, the weight of the engine <b>216</b> and transmission <b>218</b> is centered substantially directly over the wheel axis of the front wheels <b>226</b>, <b>228</b>, which will improve the traction and handling of the motor vehicle <b>1</b>.

Referring to <figref idref="DRAWINGS">FIGS. 1-3</figref> and <b>14</b> and <b>15</b>, the crash energy absorption assembly <b>300</b> is attached to the first side <b>118</b> of the bulkhead <b>102</b> at two attachment mounts <b>126</b><i>e</i>, <b>126</b><i>f </i>generally located laterally outside of the attachment mounts <b>126</b><i>a-d </i>for the drive train assembly <b>200</b>. The crash energy absorption assembly <b>300</b> is preferably fixedly mounted to the two attachment mounts <b>126</b><i>e</i>, <b>126</b><i>f</i>. The crash energy absorption assembly <b>300</b> is used to absorb impact energy during a collision involving the modular front end <b>10</b> of the motor vehicle <b>1</b> and to manage the energy to avoid injury to occupants of the passenger compartment <b>124</b>. The crash energy absorption assembly <b>300</b> is pre-assembled and attached to the bulkhead <b>102</b> in a similar manner to the drive train assembly <b>200</b> discussed hereinabove.

The crash energy absorption assembly <b>300</b> is generally comprised of an elongated bumper beam <b>302</b>, a pair of brackets <b>304</b>, <b>306</b>, and a pair of elongated tubes <b>308</b>, <b>310</b>. The brackets <b>304</b>, <b>306</b> are attached to the bumper beam <b>302</b>, preferably by mechanical means. The brackets <b>304</b>, <b>306</b> are preferably taper and flare brackets. In <figref idref="DRAWINGS">FIGS. 14 and 15</figref> only the right side or driver's side bracket <b>304</b> is illustrated as a taper and flare bracket. The left or passenger's side bracket <b>306</b> (top of <figref idref="DRAWINGS">FIGS. 14 and 15</figref>) is illustrated as a conventional bracket. The term “brackets <b>304</b>, <b>306</b>” is intended to represent both taper and flare and conventional brackets in this disclosure. A suitable taper and flare bracket arrangement for the brackets <b>304</b>, <b>306</b> is disclosed in U.S. patent application Ser. No. 09/932,673 to Summe et al., which is assigned to the common Assignee of this application, and is incorporated herein by reference in its entirety. The brackets <b>304</b>, <b>306</b>, when provided as taper and flare brackets, perform the function of tapering and flaring the tubes <b>308</b>, <b>310</b> from the bumper beam <b>302</b>. When the brackets <b>304</b>, <b>306</b> are conventional brackets, the elongated tubes <b>308</b>, <b>310</b> are preferably crush tubes, which accommodate impact energy involving the modular front end <b>10</b> and the crash energy absorption assembly <b>300</b>.

The tubes <b>308</b>, <b>310</b> each have a first end <b>312</b> and a second end <b>314</b>. The first ends <b>312</b> of the tubes <b>308</b>, <b>310</b> are supported by the brackets <b>304</b>, <b>306</b>. The brackets <b>304</b>, <b>306</b> each define a socket <b>316</b> for receiving and supporting the tubes <b>308</b>, <b>310</b>. The first ends <b>312</b> of the tubes <b>308</b>, <b>310</b> are received and secured in the sockets <b>316</b> defined by the brackets <b>304</b>, <b>306</b>, preferably by mechanical means, which may include an interference fit. The second ends <b>314</b> of the tubes <b>308</b>, <b>310</b> are configured for connection to the two outer attachment mounts <b>126</b><i>e</i>, <b>126</b><i>f </i>formed on the first side <b>118</b> of the bulkhead <b>102</b>. The tubes <b>308</b>, <b>310</b> may be made of aluminum or aluminum alloy such as 7003 T6, 6082 T6 aluminum alloys, other aluminum alloys such as 6061 T6 aluminum alloy, high strength steels, or non-metallic materials such as fiber reinforced polymer composite materials. Any of the 6XXX and 7XXX aluminum alloys as designated by the Aluminum Association may be used for the tubes <b>308</b>, <b>310</b>.

The tubes <b>308</b>, <b>310</b> may be at least partially or fully filled with polymeric foam <b>318</b>. Preferably, the polymeric foam <b>318</b> is located at least within the second ends <b>314</b> of the tubes <b>308</b>, <b>310</b>. The tubes <b>308</b>, <b>310</b> have hollow cross sectional profiles for receiving the polymeric foam <b>318</b>. The tubes <b>308</b>, <b>310</b> may have different cross sectional profiles, but it is generally preferred that the tubes <b>308</b>, <b>310</b> have the same cross sectional profiles. As shown in <figref idref="DRAWINGS">FIGS. 14 and 15</figref>, the cross sectional profiles for the tubes <b>308</b>, <b>310</b> may be oval or a polygonal shape such as a double hexagon, “figure-8” profile. Other possible cross sectional profiles for the tubes <b>308</b>, <b>310</b> include circular, square, rectangular, and combinations of these profiles and the oval and hexagonal profiles illustrated. Oval or circular cross sectional profiles are preferred for use with taper and flare brackets, while any of the cross sectional profiles indicated hereinabove may be used when the tubes <b>308</b>, <b>310</b> are provided as crush tubes, which are used with traditional, for example stamped steel, brackets.

As stated previously, the brackets <b>304</b>, <b>306</b> may be both taper and flare brackets, or both conventional brackets. In <figref idref="DRAWINGS">FIGS. 14 and 15</figref>, the left (passenger's) side bracket <b>306</b> is illustrated as a conventional bracket while the right or driver's side bracket <b>302</b> is illustrated as a taper and flare bracket. When the brackets <b>304</b>, <b>306</b> are conventional (i.e., can be made of any specified material but the design is conventional), the tubes <b>308</b>, <b>310</b> are provided as crush tubes that absorb crash energy by crushing or collapsing during a collision involving the modular front end <b>10</b>.

The bumper beam <b>302</b> has a generally curved shape. Since the bumper beam <b>302</b> has a generally curved shape, front impact forces on the bumper beam <b>302</b> will generate a significant cross spreading force. To counter this, the brackets <b>304</b>, <b>306</b> are connected by a crosstie <b>320</b>, which manages the transverse spreading force. The crosstie <b>320</b> interconnects the brackets <b>304</b>, <b>306</b> for stability. The bumper beam <b>302</b>, brackets <b>304</b>, <b>306</b>, and tubes <b>308</b>, <b>310</b> are preferably each made of aluminum or aluminum alloy. The bumper beam <b>302</b> is preferably made of 6013 T6 or 6061 T6 aluminum sheet that is roll formed into an open cross sectional shape. The bumper beam <b>302</b> may be made of an aluminum alloy selected from the 6XXX or 7XXX series aluminum alloys. Generally, the bumper beam <b>302</b> defines an open cross sectional shape that is at least partially, preferably completely, filled with polymeric foam <b>322</b>. The bumper beam <b>302</b> may also be made of other aluminum alloys such as 7003 T6 or 6082 T6 aluminum alloys, or other alloys selected from the 6XXX or 7XXX series aluminum alloys, or be made from high strength steel sheet. The bumper beam <b>302</b> preferably defines a substantially Σ-shaped open cross section. The substantially Σ-shaped cross section comprises a rear wall <b>324</b> connected to substantially parallel top and bottom walls <b>326</b>, <b>328</b>. A suitable bumper beam <b>302</b> having the Σ-shaped open cross section described hereinabove is found in U.S. Pat. No. 6,308,999 to Tan et al. assigned to Alcoa Inc., Pittsburgh, Pa., the common assignee of this application, and is incorporated herein in its entirety.

The brackets <b>304</b>, <b>306</b> are preferably aluminum alloy extrusions and are preferably taper and flare brackets as indicated previously. Suitable aluminum alloys for the taper and flare brackets include 7003 T6 and 6082 T6 aluminum alloys. Again, however, the taper and flare brackets <b>304</b>, <b>306</b> may be made of an aluminum alloy selected from the 6XXX or 7XXX series aluminum alloys. The brackets <b>304</b>, <b>306</b> may also be made from other materials such as high strength steel and non-metallic composite materials such as polymer fibers such as carbon, glass, or arimid. The brackets <b>304</b>, <b>306</b> are preferably mechanically attached to the bumper beam <b>302</b> opposite the rear wall <b>324</b> in the Σ-shaped cross section of the bumper beam <b>302</b>.

The crash energy absorption assembly <b>300</b> is provided as a pre-assembled unit for attachment to the bulkhead <b>302</b> in a similar manner to the drive train assembly <b>200</b> discussed previously. The use of aluminum or aluminum alloys in the components of the crash energy absorption assembly <b>300</b> reduces the weight of the assembly <b>300</b> without sacrificing the energy absorbing requirements of the assembly <b>300</b>. Further, the positioning of the crash energy absorption assembly <b>300</b> generally around the drive train assembly <b>200</b> enhances the overall compactness of the modular front end <b>10</b> of the present invention.

Referring to <figref idref="DRAWINGS">FIGS. 1-3</figref> and <b>16</b>-<b>19</b>, the apron assembly <b>400</b> is generally positioned on top of the drive train assembly <b>200</b> and the crash energy absorption assembly <b>300</b>. The apron assembly <b>400</b> is pre-assembled and attached to the bulkhead <b>102</b> in a similar manner to the drive train assembly <b>200</b> and crash energy absorption assembly <b>300</b> discussed previously. The apron assembly <b>400</b> generally extends around the circumference of the engine compartment <b>122</b> defined by the modular front end <b>10</b>. The apron assembly <b>400</b> generally collects the miscellaneous engine accessories of the motor vehicle <b>1</b> and provides convenient locations for mounting these accessories.

The apron assembly <b>400</b> is generally comprised of a unitary apron member <b>402</b> having a depending front portion <b>404</b> and an apron rail <b>406</b> attached to a top end of the apron member <b>402</b>. The apron member <b>402</b> is substantially C-shaped. The apron member <b>402</b> preferably defines a plurality of integrally formed accessory attachment mounts <b>408</b>. The apron <b>406</b> rail is also substantially C-shaped and is attached to the top end of the apron member <b>402</b>. The apron rail <b>406</b> has two ends <b>410</b>, <b>412</b> configured for attachment to the bulkhead <b>102</b>. In particular, the ends <b>410</b>, <b>412</b> are configured for connection to two (2) attachment mounts <b>126</b><i>g</i>, <b>126</b><i>h </i>located adjacent the top end <b>112</b> of the bulkhead <b>102</b>. The connections between the ends <b>410</b>, <b>412</b> and the attachment mounts <b>126</b><i>g</i>, <b>126</b><i>h </i>are preferably made by mechanical fasteners.

The apron member <b>402</b> is preferably a unitary member made of molded plastic having the accessory attachment mounts <b>408</b> integrally formed therewith. The apron rail <b>406</b> is preferably a one-piece, aluminum, and preferably hydro-formed rail having differing cross sections along its length and is attached to the apron member <b>402</b> mechanically. The differing cross sections provide additional locations for mounting front end accessories used in the modular front end <b>10</b>. The accessory attachment mounts <b>408</b> may include integrally formed mounting points or openings defined in the apron member <b>402</b> for supporting various front end accessories

As stated, the apron assembly <b>400</b> generally collects the miscellaneous front end engine accessories of the motor vehicle <b>1</b>, which otherwise must be individually assembled to the front end of the motor vehicle <b>1</b>. Examples of such accessories include, but are not limited to, the radiator, coolant overflow bottle, transmission oil cooler, air conditioner condenser, fans, headlights, horn, battery, electrical fuse box, integral wire harnesses, windshield wiper washer fluid bottle, and air pump, etc. Several of the larger and more complex front end engine accessories will be discussed hereinafter. The smaller front end accessories, such as the coolant overflow bottle and windshield wiper washer fluid bottle (not shown), easily attach to the apron member <b>402</b> at the accessory attachment mounts <b>408</b> by mechanical fasteners, as will be appreciated by those skilled in the art.

The front portion <b>404</b> of the apron member <b>402</b> defines a plurality of openings, hereinafter identified as first opening <b>414</b>, second opening <b>416</b>, and third opening <b>418</b>. The first opening <b>414</b> is formed centrally in the front portion <b>404</b> and supports a radiator and cooling fan assembly <b>420</b>. The radiator and cooling fan assembly <b>420</b> is supported in the first opening <b>414</b> by conventional means, such as mechanical fasteners. The second opening <b>416</b> is defined adjacent the first opening <b>414</b> and supports an air conditioning condenser <b>422</b> of the motor vehicle <b>1</b>. The third opening <b>422</b> is defined on the other side of the first opening <b>414</b> and supports a transmission oil cooler <b>424</b>. The air conditioning condenser <b>422</b>, and transmission oil cooler <b>424</b> may be fixed in the respective second and third openings <b>416</b>, <b>418</b> by conventional means (i.e., mechanical fasteners).

The apron member <b>402</b> further comprises an integrally formed battery hold-down <b>426</b> for supporting a battery <b>426</b> of the motor vehicle <b>1</b>. The battery <b>428</b> may be supported in the battery hold-down <b>426</b> by means conventional in the art, such as straps and mechanical fasteners.

The apron assembly <b>400</b> provides a lightweight structure for collecting and supporting the miscellaneous front end accessories required for the motor vehicle <b>1</b>. The apron assembly <b>400</b> is pre-assembled in a similar manner to the drive train assembly <b>200</b> and the crash energy absorption assembly <b>300</b>. Each of the accessories attached to the apron member <b>402</b> may be pretested prior to the apron assembly <b>400</b> being attached to the bulkhead <b>102</b>. A similar procedure may be followed for the power train assembly <b>204</b>, steering and braking assembly <b>224</b>, and axle assembly <b>240</b> in the drive train assembly <b>200</b>.

Furthermore, the apron assembly <b>400</b>, particularly the apron rail <b>406</b>, provides a convenient mounting structure for fenders <b>430</b> and other front end components of the motor vehicle <b>1</b>, as indicated previously. Additionally, headlights <b>432</b> of the motor vehicle <b>1</b> may be attached to the front portion <b>404</b> of the apron member <b>402</b>, which provides a convenient location for supporting the headlights <b>432</b> of the motor vehicle <b>1</b>. The fenders <b>430</b> and headlights <b>432</b> may be attached to the apron assembly <b>400</b> by conventional means (i.e., mechanical fasteners and the like).

With the respective “modular” sub-assemblies <b>100</b>-<b>400</b> now described, a method of assembling the modular front end <b>10</b> for attachment to the motor vehicle <b>1</b> will now be discussed with reference to <figref idref="DRAWINGS">FIGS. 1-21</figref>. The method of assembling the modular front end <b>10</b> generally begins with providing the bulkhead assembly <b>100</b> having the structural members <b>128</b> and electrical components <b>130</b> pre-attached thereto. The bulkhead <b>102</b> of the bulkhead assembly <b>100</b> provides the main structural member for supporting each of the pre-assembled sub-assemblies <b>200</b>-<b>400</b> to follow. The bulkhead <b>102</b> may be provided separate from the body of the motor vehicle <b>1</b>, or pre-attached to the body of the motor vehicle <b>1</b>. The various assemblies <b>200</b>-<b>400</b> may then be mounted to the pre-attached bulkhead <b>102</b>.

Next, the drive train assembly <b>200</b> is attached to the bulkhead <b>102</b> at the four (4) drive train assembly attachment mounts <b>126</b><i>a-d </i>located on the first side <b>118</b> of the bulkhead <b>102</b>. <figref idref="DRAWINGS">FIGS. 20 and 21</figref> show the “structural elements” of the respective assemblies <b>100</b>-<b>400</b>, with all “accessories” omitted for clarity in showing the mounting connections for the drive train assembly <b>200</b>, crash energy absorption assembly <b>300</b>, and apron assembly <b>400</b>. As described previously, the drive train support <b>202</b> is affixed directly to the bulkhead <b>102</b>. The power train assembly <b>204</b>, which generally comprises the engine <b>216</b> and transmission <b>218</b> of the motor vehicle <b>1</b>, is cantilevered from the drive train support <b>202</b> and bulkhead <b>102</b>. The drive train assembly <b>200</b>, as discussed previously is provided pre-assembled, with the power train assembly <b>204</b> pre-attached to the drive train support <b>202</b> and the engine <b>216</b> and transmission <b>218</b> pre-tested. The steering gear <b>224</b>, which is connected to the steering column of the motor vehicle <b>1</b>, interconnects the lower ends <b>214</b> of the support members <b>206</b>, <b>208</b> to form a solid box frame structure, as described previously. The brake and suspensions assemblies <b>230</b> may be connected to the drive train support <b>202</b> in the manner described previously and pre-tested for function.

Once the drive train support <b>202</b> and pre-tested power train assembly <b>204</b> are attached to the bulkhead <b>102</b>, the crash energy absorption assembly <b>300</b> may be attached to the bulkhead <b>102</b> at the attachment mounts <b>126</b><i>e</i>, <b>126</b><i>f</i>, which are generally located outside of the drive train support <b>202</b> attachment mounts <b>126</b><i>a-d </i>used to support the drive train assembly <b>200</b>. The crash energy absorption assembly <b>300</b> is provided pre-assembled such that it is only necessary to attach the second ends <b>314</b> of the tubes <b>308</b>, <b>310</b> to their corresponding attachment mounts <b>126</b><i>e</i>, <b>126</b><i>f </i>on the first side <b>118</b> of the bulkhead <b>102</b>.

With the drive train assembly <b>200</b> and the crash energy absorption assembly <b>300</b> attached to the bulkhead <b>102</b>, the apron assembly <b>400</b> may be attached to the bulkhead <b>102</b>. The apron assembly <b>400</b> is attached to the bulkhead <b>102</b> by affixing the ends <b>410</b>, <b>412</b> of the apron rail <b>406</b> at the apron assembly attachment mounts <b>126</b><i>g</i>, <b>126</b><i>h </i>generally located adjacent the top end <b>112</b> of the bulkhead <b>102</b>. The apron member <b>402</b> is partially supported in the vertical direction by the tubes <b>308</b>, <b>310</b>. In particular, a bottom end of the front portion <b>404</b> of the apron member <b>402</b> rests on the tubes <b>308</b>, <b>310</b> to provide vertical support for the apron assembly <b>400</b>. The front portion <b>404</b> of the apron member <b>402</b> may be attached to the crosstie <b>320</b> connecting the brackets <b>304</b>, <b>306</b> in the crash energy absorption assembly <b>300</b>. An adhesive may be used between the bottom end of the front portion <b>404</b> of the apron member <b>402</b> and the surfaces of the tubes <b>308</b>, <b>310</b> to further secure the apron assembly <b>400</b> to the crash energy absorption assembly <b>400</b>. All attachments between the drive train assembly <b>200</b>, crash energy absorption assembly <b>300</b>, and apron assembly <b>400</b> and the bulkhead <b>102</b> are preferably made with mechanical fasteners. Rubber bushings or mounts as discussed previously may be used in the connections between the drive train assembly <b>200</b> and the bulkhead <b>102</b> to isolate these assemblies and minimize vibration as indicated previously.

In an alternative method of assembly, the apron assembly <b>400</b> may be attached first to the crash energy absorption assembly <b>300</b>. This “combined” assembly (crash energy absorption assembly <b>300</b> and apron assembly <b>400</b>) may then be attached as a unit to the bulkhead <b>102</b>. The combined crash energy absorption assembly <b>300</b> and apron assembly <b>400</b> is then attached to the bulkhead <b>102</b> in the manner described previously. Once again, the bulkhead <b>102</b> may be detached from or pre-attached to the body of the motor vehicle <b>1</b>.

The modular front end of the present invention results in higher quality motor vehicles and reduced costs to the manufacturer. Motor vehicle assembly lines may be shortened because the “sub-modules” or sub-assemblies described hereinabove collect numerous individual parts that previously had to be individually assembled to the motor vehicle. Accordingly, an increased number of car bodies may be put through the assembly line in a given period of time. The modular front end also reduces the mass of the motor vehicle, which improves performance and the fuel efficiency of the motor vehicle. Additionally, the modular front end preferably uses mechanical fasteners at all connection points rather than metallurgical joints, which reduces production time and cost. In general, the modular front end of the present invention improves the speed and quality at which motor vehicles are constructed.